Maximising ROI with High-Efficiency Compressed Air for Glasgow Packaging
Serving customers throughout the Central Belt and Scotland, including Glasgow, Edinburgh, Dundee, Fife, Stirling, and Perth, our certified engineers use advanced flow monitoring technology to visualise your compressed air usage and identify waste.
Contact us today to speak to our experts about flow monitoring. Our team is ready to help you stop paying for air you do not use.
Project Overview
A prominent packaging manufacturer based in Glasgow recently reached out to Design Air to support the expansion of their facility. With the introduction of several new, high-speed packaging lines, the client required a compressed air system that could deliver consistent air quality and volume without driving up their long-term operational costs.
At Design Air, our approach is always built on transparency. We didn’t just provide a quote for a machine; we provided a detailed analysis of how the client could turn their utility bill into a competitive advantage.
The Challenge: Upfront Cost vs. Total Lifecycle Value
The primary challenge for this project was balancing the initial capital expenditure (CAPEX) with the ongoing operational expenditure (OPEX). During the consultation phase, we presented the client with two clear pathways:
The Fixed Speed Option
A standard rotary screw compressor. While this was approximately £6,000 cheaper to purchase initially, it would run at a constant speed regardless of demand, leading to significant energy waste during lower-demand periods.
The VSDs Innovation
An Atlas Copco Variable Speed Drive (VSDs) system. This option carried a higher upfront cost but promised to dramatically reduce energy consumption by matching motor speed exactly to the plant’s air demand.
By being fair and honest in our assessment, we demonstrated that the cheaper machine was actually the more expensive choice over time.
The Solution: A Fully Integrated Atlas Copco System
The client opted for the high-efficiency route. Our engineering team designed and installed a comprehensive system tailored to the rigours of 24/7 packaging operations:
Atlas Copco GA22VSDs Compressor
The heart of the system. This latest-generation variable-speed rotary screw compressor provides industry-leading efficiency, reducing energy consumption by up to 60% compared to fixed-speed models.
UD Two-in-One Filter
To ensure the air entering the packaging lines is free from contaminants, we installed the UD filter. This innovative technology provides two levels of filtration in a single housing, resulting in a 40% lower pressure drop and increased energy efficiency.
FX Refrigerant Dryer
To prevent moisture from damaging sensitive pneumatic components and the packaging, the FX dryer maintains a stable dew point and reliably removes moisture.
OSC Oil-Water Separator & Galvanised Dry Air Receiver
We rounded out the system with a 250L galvanised receiver for air storage and an OSC separator to ensure the client remains fully compliant with environmental regulations regarding condensate disposal.
The Results: £4,000 Annual Savings
The impact of choosing the VSD technology was immediate and quantifiable. Our energy audit and projections showed:
- Estimated Annual Energy Savings: £4,000 per year.
- Rapid Return on Investment: The £6,000 price difference between the fixed-speed and VSD models will be fully recouped in just 18 months.
- Carbon Footprint Reduction: Beyond the financial savings, the reduction in energy usage aligns with the client’s sustainability goals, significantly lowering their carbon output in the Glasgow area.
The Design Air Standard
As Scotland’s compressed air specialists, we ensured the entire installation met the highest professional standards. This included full compliance with Pressure Systems Safety Regulations (PSSR 2000), providing the client with complete peace of mind and a system that is built to last.
From initial design to final commissioning, our goal was to be more than just a supplier. We are a partner in our client’s growth, helping them make informed, data-driven decisions that benefit their bottom line.
Looking to optimise your own air system? Whether you are based in Glasgow or across Scotland, our experts are ready to provide honest advice and tailored solutions for any budget. Get in touch with Design Air today for an energy audit or equipment consultation.